Process for coating fluoroelastomer fuser member using fluorinated surfactant

ABSTRACT

A process for producing a fuser member coating including a) adding and reacting a fluoroelastomer, a crosslinking agent, a polar solvent, and a fluorinated copolymer surfactant to form a coating solution, and b) providing the coating solution on the fuser member to form a fuser member coating, wherein the fluorinated copolymer surfactant includes a copolymer selected from the group consisting of a fluorinated acrylate copolymer and a fluorinated polyether copolymer.

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is directed to copending, commonly-assigned 1) U.S.application No. ______ (Attorney Docket Number 20040371), filed ______,entitled, “Process for Coating Fluoroelastomer Fuser Member UsingFluorinated Polydimethylsiloxane Additive;” 2) U.S. application No.______ (Attorney Docket Number 20040371Q1), filed ______, entitled,“Process for Coating Fluoroelastomer Fuser Member Using FluorinatedSurfactant and Fluorinated Polydimethylsiloxane Additive Blend;” 3) U.S.application No. ______ (Attorney Docket Number 20040371 Q2), filed______, entitled, “Process for Coating Fluoroelastomer Fuser MemberUsing Blend of Two Different Fluorinated Surfactants;” 4) U.S.application No. ______ (Attorney Docket Number 20041027), filed ______,entitled, “Fuser Member Comprising Deflocculated Material;” and 5) U.S.application No. ______ (Attorney Docket Number 20041027Q), filed ______,entitled, “Process for Coating Fluoroelastomer Fuser Member Using Blendof Deflocculated Material and Polydimethylsiloxane Additive;” thesubject matter of these applications is hereby incorporated by referencein their entirety.

BACKGROUND

Herein are disclosed fuser members useful in electrostatographicreproducing apparatuses, including digital, image on image, and contactelectrostatic printing apparatuses. The present fuser members can beused as fuser members, pressure members, transfuse or transfix members,and the like. In an embodiment, the fuser members comprise an outerlayer comprising a fluoroelastomer. In embodiments, the outer layer ofthe fuser member is prepared by addition of a fluorinated copolymersurfactant in a process for coating a fuser member.

In a typical electrostatographic reproducing apparatus, a light image ofan original to be copied is recorded in the form of an electrostaticlatent image upon a photosensitive member, and the latent image issubsequently rendered visible by the application of electroscopicthermoplastic resin particles and pigment particles, or toner. Thevisible toner image is then in a loose powdered form and can be easilydisturbed or destroyed. The toner image is usually fixed or fused upon asupport, which may be the photosensitive member itself, or other supportsheet such as plain paper.

The use of thermal energy for fixing toner images onto a support memberis well known. To fuse electroscopic toner material onto a supportsurface permanently by heat, it is usually necessary to elevate thetemperature of the toner material to a point at which the constituentsof the toner material coalesce and become tacky. This heating causes thetoner to flow to some extent into the fibers or pores of the supportmember. Thereafter, as the toner material cools, solidification of thetoner material causes the toner material to be firmly bonded to thesupport.

Typically, the thermoplastic resin particles are fused to the substrateby heating to a temperature of between about 90 to about 200° C. orhigher depending upon the softening range of the particular resin usedin the toner. It may be undesirable; however, to increase thetemperature of the substrate substantially higher than about 250° C.because of the tendency of the substrate to discolor or convert intofire at such elevated temperatures, particularly when the substrate ispaper.

Several approaches to thermal fusing of electroscopic toner images havebeen described. These methods include providing the application of heatand pressure substantially concurrently by various means, a roll pairmaintained in pressure contact, a belt member in pressure contact with aroll, a belt member in pressure contact with a heater, and the like.Heat may be applied by heating one or both of the rolls, plate members,or belt members. The fusing of the toner particles takes place when theproper combinations of heat, pressure and contact time are provided. Thebalancing of these parameters to bring about the fusing of the tonerparticles is well known in the art, and can be adjusted to suitparticular machines or process conditions.

During operation of a fusing system in which heat is applied to causethermal fusing of the toner particles onto a support, both the tonerimage and the support are passed through a nip formed between the rollpair, or plate or belt members. The concurrent transfer of heat and theapplication of pressure in the nip affect the fusing of the toner imageonto the support. It is important in the fusing process that no offsetof the toner particles from the support to the fuser member takes placeduring normal operations. Toner particles offset onto the fuser membermay subsequently transfer to other parts of the machine or onto thesupport in subsequent copying cycles, thus increasing the background orinterfering with the material being copied there. The referred to “hotoffset” occurs when the temperature of the toner is increased to a pointwhere the toner particles liquefy and a splitting of the molten tonertakes place during the fusing operation with a portion remaining on thefuser member. The hot offset temperature or degradation of the hotoffset temperature is a measure of the release property of the fuserroll, and accordingly it is desired to provide a fusing surface, whichhas a low surface energy to provide the necessary release. To ensure andmaintain good release properties of the fuser roll, it has becomecustomary to apply release agents to the fuser roll during the fusingoperation. Typically, these materials are applied as thin films of, forexample, nonfunctional silicone oils or mercapto- or amino-functionalsilicone oils, to prevent toner offset.

U.S. Pat. No. 4,515,884 to Field et al. discloses a fuser member havinga silicone elastomer-fusing surface, which is coated with a tonerrelease agent, which includes an unblended polydimethyl siloxane.

U.S. Pat. No. 6,197,989 B1 to Furukawa et al. discloses afluorine-containing organic silicone compound represented by a formula.

U.S. Pat. No. 5,736,250 teaches a crosslinked polysiloxane andfluoroelastomer layer.

U.S. Pat. No. 5,716,747 to Uneme et al. discloses a fluororesin coatedfixing device with a coating of a fluorine containing silicone oil.

U.S. Pat. No. 5,698,320 to Ebisu et al. discloses a fixing device coatedwith a fluororesin, and having a fluorosilicone polymer release agent.

U.S. Pat. No. 5,641,603 to Yamazaki et al. discloses a fixing methodusing a silicone oil coated on the surface of a heat member.

U.S. Pat. No. 5,636,012 to Uneme et al. discloses a fixing device havinga fluororesin layer surface, and using a fluorine-containing siliconeoil as a repellant oil.

U.S. Pat. No. 5,627,000 to Yamazaki et al. discloses a fixing methodhaving a silicone oil coated on the surface of the heat member, whereinthe silicone oil is a fluorine-containing silicone oil and has aspecific formula.

U.S. Pat. No. 5,624,780 to Nishimori et al. discloses a fixing memberhaving a fluorine-containing silicone oil coated thereon, wherein thesilicone oil has a specific formula.

U.S. Pat. No. 5,568,239 to Furukawa et al. discloses a stainproofing oilfor heat fixing, wherein the fluorine-containing oil has a specificformula.

U.S. Pat. No. 5,463,009 to Okada et al. discloses a fluorine-modifiedsilicone compound having a specific formula, wherein the compound can beused for oil-repellency in cosmetics.

U.S. Pat. No. 4,968,766 to Kendziorski discloses a fluorosiliconepolymer for coating compositions for longer life.

Known processes for providing surfaces of fuser members include dippingthe substrate into a bath of coating solution or spraying the peripheryof the substrate with the coating material. Another process forproviding surfaces of fuser members involves dripping material spirallyover a horizontally rotating cylinder. Generally, in this flow coatingmethod, the coating is applied to the substrate by rotating thesubstrate in a horizontal position about a longitudinal axis andapplying the coating from an applicator to the substrate in a spiralpattern in a controlled amount so that substantially all the coatingthat exits the applicator adheres to the substrate. For specific detailsof an embodiment of the flow coating method, attention is directed toU.S. Pat. No. 5,945,223, entitled “Flow Coating Solution and FuserMember Layers Prepared Therewith” and to U.S. Pat. No. 6,408,753 andU.S. Pat. No. 6,521,330, entitled “Flow Coating Process for Manufactureof Polymeric Printer and Belt Components,” and to U.S. Pat. No.6,479,158, entitled “Fuser Member with an Amino Silane Adhesive Layerand Preparation Thereof,” the disclosures of which are herebyincorporated by reference in their entirety. For specific details of anembodiment of fuser roll top coat compositions, attention is directed toU.S. Pat. No. 5,332,641, entitled “Fuser Member with an Amino SilaneAdhesive Layer,” the disclosure of which is hereby incorporated byreference in its entirety.

However, not all coatings are compatible with the flow coating method.Specifically, only materials that can be completely dissolved in asolvent can be flow coated. Further, it is desirable that the materialhave the ability to stay dissolved during the entire flow coatingprocess which may take up to approximately 8 hours or longer, and muststay dissolved during the manufacturing period which may be up toseveral days. Good results are not obtained with materials which tend tocoagulate or crystallize within the time period required for flowcoating, which may be on the order of about 8 hours and for productionmanufacturing, may be on the order of a few days, for example, fromabout 1 to about 4 days. It is desirable to use a material capable ofbeing flow coated for an increased amount of time to enable flow coatingin a manufacturing and production environment. It is very costly toperiodically shut down a manufacturing line and change the solutiondelivery system. If the coating does not have the desired properties,the assembly line may need to be shut down often, for example, everyhour or every few hours in order to clean the delivery line ofcoagulated or crystallized material. Therefore, it is desirable to use amaterial that has good flow coating properties in order to allow formanufacturing to continue for a long period of time, for example severaldays, without incurring the above problems in the procedure.

It is also desirable that the coating be slow drying to avoid trappingsolvent in the under layers which tends to cause bubbles and solvent“pops.” Bubbles result from trapped air in the coating which results innon-uniformity of coating and or surface defects. Solvent “pops” aredefined as trapped air or solvent voids that rupture resulting incrater-like structures causing non-uniform coated areas or surfacedefects. In either case, these defects can act as initiation sites foradhesion failures.

Moreover, useful materials for the flow coating process must possess theability to flow in a manner that allows for the entire roll to becoated. Therefore, it is desirable that the material possess a desiredviscosity which allows it to flow over the entire surface of the memberbeing coated. Along with these properties, it is desirable that thematerial to be coated possess a balance between viscosity and percentsolids. Similarly, it is desirable that the coating material have theability to completely dissolve in a solvent in order to preventprecipitation of the material that can lead to non-uniform flow coating,and imperfections in the final flow coated surface.

The balance between viscosity and percent solids is desired to enablesufficient build rates, which impact throughput and work in process.Build rates are defined as the thickness of a material that can becoated per unit time. The thickness of the material should allow for abalance between maintaining thickness uniformity and avoiding solvent“pops” and air bubbles. Throughput in the process is the number of unitsthat are processed per unit time. Work in process is the number of unitscurrently in any one of the process stages from beginning to end. Theobjective is to maximize the build rate and reduce the throughput timeand work in process.

Many materials are known to be useful for outer coatings of a fusermember, such as for example, silicone rubbers, fluoropolymers andfluoroelastomers, which possess some of the above qualities necessaryfor flow coating. However, problems may result once the fluoroelastomeris dissolved in a solvent and crosslinking or curing agents are added.For example, the curative or crosslinking agents tend to precipitatewithin minutes after addition to the solvent solutions. The precipitatecauses numerous problems such as clogging the filters and pumps used inthe flow coating process. Further, the entire fuser member cannot becoated due to early precipitation of the curing and/or crosslinkingagent. In addition, early precipitation may lead to non-uniform flowcoating and imperfections in the final flow coated surface. A flowcoating solution that minimizes these deficiencies is described in U.S.Pat. No. 5,945,223.

Fuser member layers produced by the flow coating process sometimesexhibit additional defects that may occur particularly when the coatingsare very thin, for example less than 50 micrometers in thickness. Thesedefects include “snowflake agglomerates,” due to agglomeration ofparticles such as barium sulfate added to certain fluoroelastomers toprevent the fluoroelastomer pellets from sticking together, and“fisheyes,” which are typically 1 to 5 millimeter regions either devoidof a fluoroelastomer layer, or with a very thin fluoroelastomer layer.

Such defects in the fuser member layer can cause undesirable imagedefects on the printed copy, such as toner spots, toner picking (i.e.,removal of toner leaving white spots), non-uniform gloss, hot offset,and poor image permanence. There exists a need for a flow coatingsolution that forms a fuser member layer surface that is smooth and freeor substantially free of such defects.

U.S. Pat. No. 4,571,371 discloses silicone used as a leveling agent inphotoreceptor transport layers.

U.S. Pat. Nos. 5,750,204, 5,753,307, 5,700,568 and 5,695,878 to Badesha,et al. teach formulations for fluoroelastomer fuser outer membersurfaces using an amino silane as a crosslinking agent.

U.S. Pat. No. 5,595,823 to Chen, et al., U.S. Pat. Nos. 5,729,813 and6,159,588 to Eddy, et al., and U.S. Pat. No. 6,395,444 to Riehle, et al.disclose fluoroelastomer fuser outer layer compositions for high thermalconductivity.

U.S. Pat. No. 5,547,759 to Chen, et al., discloses formulations forfluoroelastomer coatings for fuser members.

U.S. Pat. Nos. 6,207,243, 6,114,041 and 5,935,712 to Tan, et al.,disclose fuser member fluoroelastomer formulations with surface-treatedthermally conductive fillers.

U.S. Pat. No. 6,696,158 to Chen, et al. discloses a fluorocarbonthermoplastic coating for fuser members.

U.S. Pat. No. 6,218,014 to Pickering, et al. discloses fluorocarbonfuser members with silicon carbide filler.

U.S. Pat. No. 6,514,650 to Schlueter, Jr. et al. teaches a thinperfluoropolymer outer coating for fuser members.

U.S. Pat. No. 6,721,529 to Chen, et al. discloses a fluoroelastomercoating composition for release agent donor members.

Currently, an acrylate copolymer with pendant glycol and perfluorooctanesulfonate groups has shown success in reducing snowflake agglomeratesand fisheyes when used as a surfactant/leveling agent additive influoroelastomer coating solutions. However, this copolymer has beenshown to demonstrate environmental persistence problems and can nolonger be used. Use of other similar materials has resulted in theformation of fisheyes and/or snowflake agglomerates. Therefore, it isdesired to provide a fluoroelastomer fuser member layer that reduces oreliminates surface defects, including fisheyes and snowflakeagglomerates, and that performs well as a fuser member, and does notdegrade other properties or desired features of the fuser member layer.

SUMMARY

Embodiments include a process for producing a fuser member coatingcomprising a) adding and reacting a fluoroelastomer, a crosslinkingagent, a polar solvent, and a fluorinated copolymer surfactant to form acoating solution, and b) providing the coating solution on the fusermember to form a fuser member coating, wherein the fluorinated copolymersurfactant comprises a copolymer selected from the group consisting of afluorinated acrylate copolymer and a fluorinated polyether copolymer.

Embodiments further include a process for producing a fuser membercoating comprising a) adding and reacting a fluoroelastomer, acrosslinking agent, a polar solvent, and a fluorinated acrylatecopolymer surfactant having pendant groups selected from the groupconsisting of perfluoroalkyl sulfonate, glycol, and fluorinated alkylgroups, to form a coating solution, and b) providing the coatingsolution on the fuser member to form a fuser member coating.

In addition, embodiments include a process for producing a fuser membercoating comprising a) adding and reacting a fluoroelastomer, acrosslinking agent, a polar solvent, and a fluorinated polyethercopolymer surfactant having pendant trifluoroethoxy groups to form acoating solution, and b) providing the coating solution on the fusermember to form a fuser member coating.

Moreover, embodiments include a process for producing a fuser membercoating comprising a) adding and reacting a fluoroelastomer, acrosslinking agent, a polar solvent, and a fluorinated copolymersurfactant to form a coating solution, and b) providing the coatingsolution on the fuser member to form a fuser member coating, wherein thefluorinated copolymer surfactant comprises a copolymer selected from thegroup consisting of a fluorinated acrylate copolymer and a fluorinatedpolyether copolymer, and further wherein the fluoroelastomer is selectedfrom the group consisting of a) copolymers of two of vinylidenefluoride, hexafluoropropylene, and tetrafluoroethylene, b) terpolymersof vinylidene fluoride, hexafluoropropylene, and tetrafluoroethylene,and c) tetrapolymers of vinylidene fluoride, hexafluoropropylene,tetrafluoroethylene, and a cure site monomer.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference may behad to the accompanying figures.

FIG. 1 is a schematic illustration of an image apparatus in accordancewith an embodiment.

FIG. 2 is an enlarged, side view of an embodiment of a fuser member,showing a fuser member with a substrate, intermediate layer, outerlayer, and release agent coating layer.

DETAILED DESCRIPTION

Herein are described fuser member outer layers comprising afluoroelastomer, and prepared by addition of a fluorinated copolymer asa surfactant during coating of the fluoroelastomer outer layer. Theprocess, in embodiments, provides a fuser member outer layer thatperforms well as a fuser member, and reduces or eliminates the problemsof fisheyes and snowflake agglomerates. In addition, the fuser memberlayers are smooth, in embodiments, and have improved mechanical andchemical properties. Moreover, in embodiments, the occurrence of hotoffset and stripping failures are reduced or eliminated. Further, inembodiments, image quality is enhanced.

Referring to FIG. 1, in a typical electrostatographic reproducingapparatus, a light image of an original to be copied is recorded in theform of an electrostatic latent image upon a photosensitive member andthe latent image is subsequently rendered visible by the application ofelectroscopic thermoplastic resin particles, which are commonly referredto as toner. Specifically, photoreceptor 10 is charged on its surface bymeans of a charger 12 to which a voltage has been supplied from powersupply 11. The photoreceptor is then imagewise exposed to light from anoptical system or an image input apparatus 13, such as a laser and lightemitting diode, to form an electrostatic latent image thereon.Generally, the electrostatic latent image is developed by bringing adeveloper mixture from developer station 14 into contact therewith.Development can be effected by use of a magnetic brush, powder cloud, orother known development process. A dry developer mixture usuallycomprises carrier granules having toner particles adheringtriboelectrically thereto. Toner particles are attracted from thecarrier granules to the latent image forming a toner powder imagethereon. Alternatively, a liquid developer material may be employed,which includes a liquid carrier having toner particles dispersedtherein. The liquid developer material is advanced into contact with theelectrostatic latent image and the toner particles are deposited thereonin image configuration.

After the toner particles have been deposited on the photoconductivesurface, in image configuration, they are transferred to a copy sheet 16by transfer means 15, which can be pressure transfer or electrostatictransfer. Alternatively, the developed image can be transferred to anintermediate transfer member, or bias transfer member, and subsequentlytransferred to a copy sheet. Examples of copy substrates include paper,transparency material such as polyester, polycarbonate, or the like,cloth, wood, or any other desired material upon which the finished imagewill be situated.

After the transfer of the developed image is completed, copy sheet 16advances to fusing station 19, depicted in FIG. 1 as fuser roll 20 andpressure roll 21 (although any other fusing components such as fuserbelt in contact with a pressure roll, fuser roll in contact withpressure belt, and the like, are suitable for use with the presentapparatus), wherein the developed image is fused to copy sheet 16 bypassing copy sheet 16 between the fusing and pressure members, therebyforming a permanent image. Alternatively, transfer and fusing can beeffected by a transfix application.

Photoreceptor 10, subsequent to transfer, advances to cleaning station17, wherein any toner left on photoreceptor 10 is cleaned therefrom byuse of a blade (as shown in FIG. 1), brush, or other cleaning apparatus.

FIG. 2 is an enlarged schematic view of an embodiment of a fuser member,demonstrating the various possible layers. As shown in FIG. 2, substrate4 has intermediate layer 7 thereon. Intermediate layer 7 can be, forexample, a rubber such as silicone rubber or other suitable rubbermaterial. As shown in FIG. 2, intermediate layer 7 can have fillers 30dispersed or contained therein. The substrate and/or outer layer canalso have fillers dispersed or contained therein (fillers not shown).The optional fillers for the three layers can be the same or different.On intermediate layer 7 is positioned outer layer 5 comprising afluoroelastomer as described below. Positioned on outer fluoroelastomerlayer 5 is outermost liquid release layer 9.

The fuser member can be in the form of a roller, sheet, belt, film,drelt (hybrid between a drum and a belt), or the like. In embodiments,the fuser member is in the form of a cylindrical roller, wherein theroller substrate has a metal core, such as aluminum, steel, stainlesssteel, or the like metal substrate.

Examples of the outer surface of the fuser system members includefluoroelastomers. Specifically, suitable fluoroelastomers are thosedescribed in detail in U.S. Pat. Nos. 5,166,031, 5,281,506, 5,366,772and 5,370,931, together with U.S. Pat. Nos. 4,257,699, 5,017,432 and5,061,965, the disclosures each of which are incorporated by referenceherein in their entirety. As described therein, these elastomers arefrom the class of 1) copolymers of two of vinylidenefluoride,hexafluoropropylene, and tetrafluoroethylene; 2) terpolymers ofvinylidenefluoride, hexafluoropropylene, and tetrafluoroethylene; and 3)tetrapolymers of vinylidenefluoride, hexafluoropropylene,tetrafluoroethylene, and cure site monomer. These fluoroelastomers areknown commercially under various designations such as VITON A®, VITONB®, VITON E®, VITON E 60C®, VITON E430®, VITON 910®, VITON GH®; VITONGF®; and VITON ETP® The VITON® designation is a Trademark of E.I. DuPontde Nemours, Inc. The cure site monomer can be4-bromoperfluorobutene-1,1,1-dihydro-4-bromoperfluorobutene-1,3-bromoperfluoropropene-1,1,1-dihydro-3-bromoperfluoropropene-1,or any other suitable, known cure site monomer, such as thosecommercially available from DuPont. Other commercially availablefluoropolymers include FLUOREL 2170®, FLUOREL 2174®, FLUOREL 2176®,FLUOREL 2177® and FLUOREL LVS 76®, FLUOREL® being a Trademark of 3MCompany. Additional commercially available materials include AFLAS™ apoly(propylene-tetrafluoroethylene) and FLUOREL II® (LII900) apoly(propylene-tetrafluoroethylenevinylidenefluoride) both alsoavailable from 3M Company, as well as the Tecnoflons identified asFOR-60KIR®, FOR-LHF®, NM® FOR-THF®, FOR-TFS®, TH®, NH®, P757®, TNS®,T439®, PL958®, BR9151® and TN505®, available from Ausimont.

Examples of three known fluoroelastomers are (1) a class of copolymersof two of vinylidenefluoride, hexafluoropropylene, andtetrafluoroethylene, such as those known commercially as VITON A®; (2) aclass of terpolymers of vinylidenefluoride, hexafluoropropylene, andtetrafluoroethylene known commercially as VITON B®; and (3) a class oftetrapolymers of vinylidenefluoride, hexafluoropropylene,tetrafluoroethylene, and cure site monomer known commercially as VITONGH® or VITON GF®.

The fluoroelastomers VITON GH® and VITON GF® have relatively low amountsof vinylidenefluoride. The VITON GF® and VITON GH® have about 35 weightpercent of vinylidenefluoride, about 34 weight percent ofhexafluoropropylene, and about 29 weight percent of tetrafluoroethylenewith about 2 weight percent cure site monomer.

The thickness of the outer layer of the fuser member is from about 10 toabout 500 micrometers, or from about 10 to about 40 micrometers.

The amount of fluoroelastomer compound in solution in the outer layersolution is from about 5 to about 40 percent, or from about 16 to about22 percent by weight of total solids. Total solids as used hereininclude the amount of fluoroelastomer, crosslinking agent, solvent,surfactant, dehydrofluorinating agent, surfactant, and optionaladjuvants and fillers, including optional metal oxide fillers.

An inorganic particulate filler may be used in connection with thefluoroelastomer outer layer, in order to provide anchoring sites for thefunctional groups of the silicone fuser agent. Examples of suitablefillers include a metal-containing filler, such as a metal, metal alloy,metal oxide, metal salt or other metal compound. The general classes ofmetals, which -are applicable herein, include those metals of Groups 1b,2a, 2b, 3a, 3b, 4a, 4b, 5a, 5b, 6b, 7b, 8 and the rare earth elements ofthe Periodic Table. The filler can be an oxide of aluminum, copper, tin,zinc, lead, iron, platinum, gold, silver, antimony, bismuth, zinc,iridium, ruthenium, tungsten, manganese, cadmium, mercury, vanadium,chromium, magnesium, nickel and alloys thereof. Other specific examplesinclude inorganic particulate fillers are aluminum oxide and cupricoxide. Other examples include reinforcing and non-reinforcing calcinedalumina and tabular alumina respectively. The filler may be included inthe substrate, and/or intermediate layer, and/or outer layer. Theoptional filler in the various layers may be the same or different.

Optional intermediate adhesive layers and/or intermediate polymer orelastomer layers may be applied to achieve desired properties andperformance objectives of the present invention. The intermediate layermay be present between the substrate and the outer fluoroelastomersurface. An adhesive intermediate layer may be selected from, forexample, epoxy resins and polysiloxanes. Examples of suitableintermediate layers include silicone rubbers such as room temperaturevulcanization (RTV) silicone rubbers; high temperature vulcanization(HTV) silicone rubbers and low temperature vulcanization (LTV) siliconerubbers. These rubbers are known and readily available commercially suchas SILASTIC® 735 black RTV and SILASTIC® 732 RTV, both from Dow Corning;and 106 RTV Silicone Rubber and 90 RTV Silicone Rubber, both fromGeneral Electric; and JCR6115CLEAR HTV and SE4705U HTV silicone rubbersfrom Dow Corning Toray Silicones. Other suitable silicone materialsinclude the siloxanes (such as polydimethylsiloxanes); fluorosiliconessuch as Silicone Rubber 552, available from Sampson Coatings, Richmond,Va.; liquid silicone rubbers such as vinyl crosslinked heat curablerubbers or silanol room temperature crosslinked materials; and the like.Another specific example is Dow Corning Sylgard 182. Commerciallyavailable LSR rubbers include Dow Corning Q3-6395, Q3-6396, SILASTIC®590 LSR, SILASTIC® 591 LSR, SILASTIC® 595 LSR, SILASTIC® 596 LSR, andSILASTIC® 598 LSR from Dow Corning.

There may be provided an adhesive layer between the substrate and theintermediate layer. There may also be an adhesive layer between theintermediate layer and the outer layer. In the absence of anintermediate layer, the fluoroelastomer layer may be bonded to thesubstrate via an adhesive layer.

The thickness of the intermediate layer is from about 0.5 to about 20mm, or from about 1 to about 10 mm.

Suitable release agents or fusing oils can be provided onto the outerlayer of the fuser member via a delivery mechanism such as a deliveryroll. The delivery roll is partially immersed in a sump, which housesthe fuser oil or release agent. The oil is renewable in that the releaseoil is housed in a holding sump and provided to the fuser roll whenneeded, optionally by way of a release agent donor roll in an amount offrom about 0.1 to about 20 mg/copy, or from about 1 to about 12 mg/copy.The system by which fuser oil is provided to the fuser roll via aholding sump and optional donor roll is well known. The release oil maybe present on the fuser member in a continuous or semicontinuous phase.The fuser oil in the form of a film is in a continuous phase andcontinuously covers the fuser member.

The fluoroelastomer fuser coating can be prepared by adding a surfactantand/or additive to the fluoroelastomer coating solution, prior tocoating of the fluoroelastomer in solution on the fuser member. Thedetails of the process are as follows.

In embodiments, coating solutions comprise a polymer and afluorine-containing material. More specifically, the coating cancomprise a polymer such as a fluoropolymer, a curative systemappropriate for the particular polymer, and additional additives toassist with curing and to improve mechanical and thermal properties ofthe coated layer. The coating solution can also comprise afluorine-containing material such as a fluorine-containing polysiloxane,or a fluorine-containing surfactant that is not a polysiloxane, or ablend of a fluorine-containing polysiloxane and a fluorine-containingsurfactant, or a blend of at least two distinguishingfluorine-containing surfactants to provide coatings that are free of orhave a reduced numbers of defects. Optionally, additives may be used toincrease pot-life to an acceptable time. All of these components areadded to a solvent in order to form a solution/dispersion, which isapplied to the fuser roll by the flow coating or other coating method.

Examples of suitable fluorine-containing polysiloxane additives includepolysiloxanes with pendant fluorinated groups, such asCF₃(CF₂)_(n)(CH₂)_(m)—. In embodiments, the polysiloxanes having pendantfluorinated groups include those having the following Formula I:

wherein m and n represent the number of repeating units and are the sameor different, and m is from about 0 to about 25 or from about 1 to about10, or from about 1 to about 5, or about 2; and n is from about 1 toabout 25, or from about 2 to about 12, or from about 3 to about 7, orabout 5. The extent of incorporation of the pendant fluorocarbon chains,defined as x/(x+y) is from about 1 percent to about 100 percent, fromabout 4 percent to about 20 percent, from about 5 to about 10 percent,or about 5.7 percent. The groups, R₁ and R₂ can be the same or differentand are selected from the group consisting of alkyl having from about 1to about 18 carbon atoms, such as methyl, ethyl, propyl, butyl and thelike; arylalkyl groups having from about 1 to about 18 carbons, such asmethylphenyl, ethylphenyl, propylphenyl, butylphenyl and the like; aminogroups; and alkylamino groups having from about 1 to about 18 carbons,such as methylamino, ethylamino, propylamino, butylamino and the like.The group R₃ is selected from the group consisting of alkyl andarylalkyl groups such as those just listed, a polyorganosiloxane chainhaving from about 1 to about 300 repeat units, and a fluoro-chain of theformula —(CH₂)_(o)—(CF₂)_(p)—CF₃ where o and p have the same ranges as mand n, respectively, but may be the same or different than m and n.

A specific example of a fluorine-containing polysiloxane additive is onehaving the following Formula II:

wherein in Formula II, x/(x+y) is about 5.7%.

In embodiments, the viscosity of the polydimethylsiloxane additive isfrom about 50 to about 2000 cS, or from about 100 to about 500 cS, orabout 220 cS.

Examples of suitable fluorinated surfactants include acrylate copolymerswith pendant glycol and/or perfluoroalkyl sulfonate groups. An exampleof a fluorinated acrylate copolymer surfactant includes one having thefollowing Formula III:

wherein m/(m+n) is from 0 to about 1, or from about 0.2 to about 0.8, orfrom about 0.5 to about 0.6; R₁ is hydrogen, or an alkyl group havingfrom about 1 to about 18 carbons, or from about 1 to about 10 carbons;and R₂ is hydrogen, an alkyl group having from about 1 to about 18carbons, or from about 1 to about 10 carbons or R₂ is a connection pointto an acrylate polymer backbone, thus creating an inter- orintra-molecular bridge; x is a number of from about 1 to about 10, orfrom about 1 to about 5, or about 3; a is a number of from about 1 toabout 50, or from about 1 to about 30, or from about 5 to about 20; b isa number of from about 1 to about 100, or from about 5 to about 50, orfrom about 10 to about 30; and c is a number of from about 1 to about50, or from about 1 to about 30, or from about 5 to about 20. Examplesof commercially available fluorine-containing surfactants falling withinthe above Formula III include Fluorad® FC-4430 and Fluorad® FC-4432,commercial products sold by 3M. For these particular surfactants:R₁═CH₃, x=3, a is about 10, b is about 20 and c is about 10. ForFluorad™ FC-4430 m/(m+n) is about 0.5, and for Fluorad™ FC-4432 m/(m+n)is about 0.6.

Examples of other suitable fluorinated surfactants include acrylatecopolymers with pendant alkyl and/or fluorinated alkyl groups. Anexample of a suitable fluorinated acrylate copolymer is one having thefollowing Formula IV:

wherein m/(m+n) is from 0 to about 1, or from about 0.1 to about 0.4, orabout 0.25; x is a number of from about 1 to about 20, or from about 5to about 10; y is a number of from about 1 to about 25, or from about 5to about 15. A commercially available example of a fluorine-containingsurfactant falling within the above Formula IV is Zonyl® FSG, acommercial product sold by E.I. DuPont de Nemours and Company. For thissurfactant, x is about 7 and y is about 11 and m/(m+n) is about 0.25.

Other examples of suitable surfactants are polyether copolymers withpendant trifluoroethoxy groups. An example of a suitable fluorinatedpolyether copolymer is one having the following Formula V:

wherein x/(x+y+z) is from about 0% to about 100%, or about 50% to about100%; y/(x+y+z) is from about 0% to about 50% or about 1% to about 20%;and z/(x+y+z) is from about 0% to about 30% or from 1% to about 10%. Acommercially available example is Polyfox® surfactant available fromOmnova.

In embodiments, the fuser member coating formulation solution comprisesa blend of a fluorine-containing polysiloxane of Formula I or II, incombination with a fluorine-containing surfactant of Formula III,Formula IV and/or Formula V. In embodiments, the fuser member coatingcomprises a blend of two different fluorinated copolymer surfactants,such as two or more of a fluorine-containing surfactant of Formula III,Formula IV, and/or Formula V.

In embodiments, the fluorine-containing polysiloxane orfluorine-containing surfactant or the blend of fluorine-containingpolysiloxane and fluorine-containing surfactant or the blend of at leasttwo fluorine-containing surfactants, is added to the fluoroelastomercoating solution in an amount of from about 0.5 to about 20 pph, or fromabout 3 to about 10 pph, wherein pph is expressed with respect to theamount of fluoroelastomer in the coating solution.

In embodiments, the blend of fluorine-containing polysiloxane andfluorine-containing surfactant contains about 0 to about 100, or fromabout 1 to about 40, or from about 5 percent to about 30 percentpolysiloxane.

Addition of a fluorine-containing polysiloxane, a fluorine-containingsurfactant, a blend of a fluorine-containing polysiloxane and afluorine-containing surfactant, or a blend of at least twofluorine-containing surfactants to the fluoroelastomer coating solution,results in formation of an outer fluoroelastomer fuser member layerwhich, in embodiments, functions well in fusing toner to a copysubstrate. The fuser member coating, in embodiments, is smooth, and hasfew, if any, defects. In embodiments, the number of fisheyes andsnowflake agglomerates are reduced or eliminated. Also, there is nodeterioration in hot offset or stripping performance and nodeterioration in image quality in embodiments.

In embodiments, the fluoroelastomer coating is applied to the fusermember substrate using the flow coating process, although otherprocesses such as dip coating and spray coating may be employed. Ingeneral, flow coating involves the deposition of a coating solution ontothe substrate by rotating the substrate about its longitudinal axis andapplying the coating from an applicator to the substrate in a spiralpattern in a controlled amount so that substantially all the coatingthat exits the applicator adheres to said substrate. The details of theflow coating procedure can be found in U.S. Pat. Nos. 5,945,223,6,408,753, 6,521,330 and in U.S. Pat. No. 6,479,158, the disclosures ofwhich are hereby incorporated by reference in their entirety.

In embodiments, the viscosity of the polydimethylsiloxane surfactant isfrom about 75 to about 1,500 cS, or from about 200 to about 1,000 cS, orabout 220 cS.

All the patents and applications referred to herein are herebyspecifically, and totally incorporated herein by reference in theirentirety in the instant specification.

The following Examples further define and describe embodiments of thepresent invention. Unless otherwise indicated, all parts and percentagesare by weight.

EXAMPLES Example I

Formation of Fuser Member Coating

A fuser member coating formulation was prepared from a solventsolution/dispersion containing 100 parts by weight of ahydrofluoroelastomer, DuPont Viton® GF, a tetrapolymer of 35 weightpercent vinylidenefluoride, 34 weight percent hexafluoropropylene, 29weight percent tetrafluoroethylene, and 2 weight percent of a cure sitemonomer. The Viton® GF was mixed with 7 parts by weight of DuPont Viton®Curative 50, 1.5 parts by weight magnesium oxide (Maglite D availablefrom C. P. Hall, Chicago, Ill.), 0.75 parts by weight calcium hydroxide,0.75 parts by weight carbon black (N990 available from R. T. VanderbiltCo.), 5.6 parts by weight Novec® FC-430 (available from 3M) in a mixtureof methylethylketone and methylisobutyl ketone, which was dispensed ontoa fuser roll surface via flow coating to a nominal thickness of about 20micrometers. The coating was cured by stepwise heating in air at 95° C.for 2 hours, 175° C. for 2 hours, 205° C. for 2 hours, and 230° C. for16 hours.

Example II

Formation of Fuser Member Coating Comprising Fluorine-ContainingSurfactant

A fuser roll topcoat formulation was prepared identically to Example Iexcept that in place of the Novec™ FC-430, 5.6 parts by weight of Novec™FC-4430 or Novec™ FC-4432, described by Formula III above, was used.

Example III

Formation of Fuser Member Coating Comprising Fluorine-ContainingPolysiloxane Additive

A fuser member coating formulation was prepared identically to Example Iexcept that in place of the Novec™ FC-430, 5.6 parts by weight of thefluorinated silicone described above in Formula II was used.

Example IV

Formation of Fuser Member Coating Comprising Blend ofFluorine-Containing Polydimethylsiloxane Additive andFluorine-Containing Surfactant

A fuser member coating formulation was prepared identically to Example Iexcept that in place of the Novec™ FC-430, a blend of 4.75 parts byweight of Novec™ FC-4430 or Novec™ FC-4432 and 1.0 parts by weight ofthe fluorinated silicone described by Formula II, were used.

Example V

Comparative Testing

The fuser member coatings prepared above were visually inspected fordefects, and the results are indicated in Table I. TABLE I Comparison ofDefects in 20 micrometer Fuser Member Coatings Prepared with DifferentAdditives Commercial Snowflake Example Manufacturer DesignationDescription Fisheyes* Agglomerates* No additive 100%  100% I 3M FC430Acrylate with pendant  1%  <1% perfluorooctanesulfonate & polyol groupsII 3M FC4430, FC4432 Acrylate with pendant 50%  <1%perfluorobutanesulfonate & polyol groups III Wacker See Formula IIFluorinated polysiloxane <1% 100% IV 3M & Wacker FC4430 & Formula IIBlend Blend of Examples II and III <1%  <1% Omnova Polyfox Polyetherwith pendant trifluoroethoxy <1% >50% containing groups DuPont Zonyl FSGCopolymer of perfluorooctyl-2-ethyl ˜50%  ˜50% methacrylate/laurylmethacrylate in Isopar H*Values refer to the percentage of rolls rejected due to the occurrenceof at least one defect.

First it should be noted that both snowflake agglomerates and fisheyedefects were present in all coatings prepared from formulation solutionsthat did not contain any fluorinated polysiloxane or fluorinatedsurfactant additives. Addition of the fluorinated surfactant FC430reduced fisheye and snowflake agglomerate defects to a very low level(Example 1). However, FC430 is no longer available. Substitution of itsreplacement, FC4430, or FC4432 in the coating solution yields a very lownumber of snowflake agglomerates. Even though the coatings have fisheyedefects (Example II), the formula is improved. Alternatively, additionof a fluorinated polysiloxane of Formula II to the coating solutionresults in a significant decrease in fisheye defects. Even though thecoatings have a snowflake agglomerates (Example III), the formula isimproved. Addition of a blend of a fluorine-containing polysiloxane anda fluorine-containing surfactant to the outer fuser member coatingsolution significantly reduces both snowflake agglomerates and fisheyedefects to very low levels (Example IV). Furthermore, fuser roll outercoatings prepared by the formulation in Example IV show no deteriorationin fuser offset performance or image quality when compared to rolls withouter coatings produced by the other formulations. Also shown in Table Iare the results from two other surfactants, Polyfox and Zonyl FSG,available from Omnova and DuPont, respectively. Polyfox additive showssignificant improvement of fisheye defects with limited improvement insnowflake agglomerate defects, while the Zonyl FSG shows a limitedreduction in both defects.

While the invention has been described in detail with reference tospecific and preferred embodiments, it will be appreciated that variousmodifications and variations will be apparent to the artisan. All suchmodifications and embodiments as may readily occur to one skilled in theart are intended to be within the scope of the appended claims.

1. A process for producing a fuser member coating comprising a) addingand reacting a fluoroelastomer, a crosslinking agent, a polar solvent,and a fluorinated copolymer surfactant to form a coating solution, andb) providing said coating solution on said fuser member to form a fusermember coating, wherein said fluorinated copolymer surfactant comprisesa copolymer selected from the group consisting of a fluorinated acrylatecopolymer and a fluoririated polyether copolymer.
 2. A process inaccordance with claim 1, wherein said fluorinated acrylate copolymercomprises a pendant perfluoroalkyl sulfonate groups.
 3. A process inaccordance with claim 2, wherein said fluorinated acrylate copolymerfurther comprises pendant glycol groups.
 4. A process in accordance withclaim 3, wherein said fluorinated acrylate copolymer has the followingFormula III:

wherein m/(m+n) is from 0 to about 1; R₁ is selected from the groupconsisting of hydrogen and an alkyl group having from about 1 to about18 carbons; R₂ is selected from the group consisting of hydrogen and analkyl group having from about 1 to about 18 carbons; x is a number offrom about 1 to about 10; a is a number of from about 1 to about 50; bis a number of from about 1 to about 100; and c is a number of fromabout 1 to about
 50. 5. A process in accordance with claim 4, whereinm/(m+n) is from about 0.2 to about 0.8.
 6. A process in accordance withclaim 4, wherein m/(m+n) is from about 0.5 to about 0.6.
 7. A process inaccordance with claim 1, wherein said fluorinated acrylate copolymer haspendant fluorinated alkyl groups.
 8. A process in accordance with claim7, wherein said fluorinated acrylate copolymer has the following FormulaIV:

wherein m/(m+n) is from 0 to about 1, x is a number of from about 1 toabout 20; and y is a number of from about 1 to about
 25. 9. A process inaccordance with claim 8, wherein said m/(m+n) is from about 0.1 to about0.4.
 10. A process in accordance with claim 9, wherein said m/(m+n) isabout 0.25.
 11. A process in accordance with claim 1, wherein saidfluorinated polyether copolymer comprises pendant trifluoroethoxygroups.
 12. A process in accordance with claim 11, wherein saidfluorinated polyether copolymer has the following Formula V:

wherein x/(x+y+z) is from about 0% to about 100%, y/(x+y+z) is fromabout 0% to about 50%, and z/(x+y+z) is from about 0% to about 30%. 13.A process in accordance with claim 1, wherein said fluoroelastomer isselected from the group consisting of a) copolymers of two of vinylidenefluoride, hexafluoropropylene and tetrafluoroethylene, b) terpolymers ofvinylidene fluoride, hexafluoropropylene, and tetrafluoroethylene, andc) tetra polymers of vinyl idene fluoride, hexafluoropropylene,tetrafluoroethylene, and a cure site monomer.
 14. A process inaccordance with claim 13, wherein said fluoroelastomer comprises about35 weight percent of vinylidenefluoride, about 34 weight percent ofhexafluoropropylene, about 29 weight percent of tetrafluoroethylene, andabout 2 weight percent cure site monomer.
 15. A process in accordancewith claim 1, wherein said coating solution is applied to said fusermember using a process selected from the group consisting of a) a flowcoating process, b) a spray coating process, and c) a dip coatingprocess.
 16. A process in accordance with claim 1, wherein said coatingsolution is applied to said fuser member in an amount to provide athickness of from about 10 to about 500 micrometers.
 17. A process inaccordance with claim 1, wherein said fluorinated copolymer surfactantis present in said coating solution in an amount of from about 0.5 toabout 20 pph based on an amount of fluoroelastomer.
 18. A process forproducing a fuser member coating comprising a) adding and reacting afluoroelastomer, a crosslinking agent, a polar solvent, and afluorinated acrylate copolymer surfactant having pendant groups selectedfrom the group consisting of perfluoroalkyl sulfonate, glycol, andfluorinated alkyl groups, to form a coating solution, and b) providingsaid coating solution on said fuser member to form a fuser membercoating.
 19. A process for producing a fuser member coating comprisinga) adding and reacting a fluoroelastomer, a crosslinking agent, a polarsolvent, and a fluorinated polyether copolymer surfactant having pendanttrifluoroethoxy groups to form a coating solution, and b) providing saidcoating solution on said fuser member to form a fuser member coating.20. A process for producing a fuser member coating comprising a) addingand reacting a fluoroelastomer, a crosslinking agent, a polar solvent,and a fluorinated copolymer surfactant to form a coating solution, andb) providing said coating solution on said fuser member to form a fusermember coating, wherein said fluorinated copolymer surfactant comprisesa copolymer selected from the group consisting of a fluorinated acrylatecopolymer and a fluorinated polyether copolymer, and further whereinsaid fluoroelastomer is selected from the group consisting of a)copolymers of two of vinylidene fluoride, hexafluoropropylene, andtetrafluoroethylene, b) terpolymers of vinylidene fluoride,hexafluoropropylene, and tetrafluoroethylene, and c) tetrapolymers ofvinylidene fluoride, hexafluoropropylene, tetrafluoroethylene, and acure site monomer.